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Most resins are thixotropic, which means if you push them hard when they are liquid they act like water, but when you leave them alone, they act like cold honey.
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Been there, done that. Exotherming polyester resin makes it thick as water but it hardens in a snap and then gets hotter than heck and has a slight amber tint.
The end result is faster but will be about 1/8" thick. I think the total thickness for the method I'm using will be about 1/16" total.
I got busy today and routed the body. The smallest bearing that came in the larger rabbit bit set was a perfect match for the flush edge router bit. No adjustment necessary except for the vertical depth adjustment.
Here are all the pieces gathered. BTW: The Mitutoyo dial calipers are 34 years old and are like new....
Here is the width of the binding. It is a little rough on the edges and I'll make adjustment for the depth of cut to sand the sides flat.
Thin stuff....a little skinnier than specified.
